Ews Lab Maual Gnit

GURUNANAK INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

(Approved by AICTE, New Delhi., NBA Accredited, Affiliated to JNTU - Hyderabad)
Ibrahimpatnam, R R District, Telangana – 501 506.
ENGINEERING WORK SHOP MANUAL (22ES0ME01)

For the Academic Year 2023-2024 [R22] I year B.Tech
MECH EWS 1
DO’S
 Dress properly for adequate physical protection.
 Use a leather apron, leather gloves and thumb guide when the need arises.
 Always put on protective glasses or goggles for eye protection.
 Use earplugs or muff when carrying out hot work.
 Always put on dust mast to get protection against saw dust and microscopic particles.
 Wear protective helmets/hard hats and safety boots when entering the workshop.
 Put on welding jackets and face shield when carrying out welding job.
DON’TS
 Do not put on loose cloths when entering the workshop.
 Do not wear jewellery when working in the workshop.
 Do not put on rings when working in the workshop.
 Do not keep a loose hair when working in the workshop.
 Do not put on metallic watches or key chains when working in the workshop.
 Do not put on metallic hard hats and bumps when carrying out electric related work.
 Do not wear bracelets while working in a workshop.
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Vision Of College
 To be a world –class educational and research institution in the service of humanity by promoting high
quality Engineering and Management Education.
Mission of College
 Imbibe soft skills and technical skills.
 Develop the faculty to reach the international standards.
 Maintain high academic standards and teaching quality that promotes the analytical thinking and
independent judgment.
 Promote research, innovation and Product development by collaboration with reputed foreign universities.
 Offer collaborative industry programs in emerging areas and spirit of enterprise.
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The Vision of the Mechanical Engineering department
 To be a leading department of Mechanical Engineering in the region
The Mission of the Mechanical Engineering department

1. Nurture young individuals into knowledgeable, skilful and ethical professionals in their pursuit of
Mechanical Engineering.
2. Nurture the faculty to expose them to world-class infrastructure.
3. Sustain high performance by excellence in teaching, research and innovations.
4. Extensive partnerships and collaborations with foreign universities for technology up gradation.
Develop Industry-Interaction for innovation and product development.
Programme Educational Objectives
 PEO 1: Graduate shall have the ability to apply knowledge and Technical skills across the disciplines and in
emerging areas of Mechanical Engineering for higher studies, research, employability and handle the
realistic problems
 PEO 2: Graduates shall possess managerial skills, maintain ethical conduct, sense of responsibility to serve
the society and protect the environment.
 PEO 3: Graduates shall possess academic excellence with innovative insight, soft skills, leadership qualities,
knowledge of contemporary issues for successful professional career.
Program Outcomes
a. An ability to apply knowledge of mathematics, science and engineering.
b. An ability to design and conduct experiments, as well as to analyze and interpret data.
c. An ability to design a system, component, or process to meet desired needs within realistic constraints
such as economic, environmental, social, political, ethical, health and safety, manufacturability, and
sustainability.
d. An ability to function on multidisciplinary teams.
e. An ability to identify, formulate, and solve engineering problems.
f. An understanding of professional and ethical responsibility.
g. An ability to communicate effectively.
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h. The broad education necessary to understand the impact of engineering solutions in aglobal, economic,
environmental, and societal context.
i. Recognition of the need for, and an ability to engage in life-long learning.
j. A knowledge of contemporary issues
k. An ability to use the techniques, skills, and modern engineering tools necessary for engineering
practice.
COURSE OUTCOMES
1. Ability to design and model different prototypes in the carpentry trade such as Crosslap joint, Dove tail joint.
2. Ability to design and model various basic prototypes in the trade of fitting such as Straightfit, V- fit.
3. Ability to make various basic prototypes in the trade of Tin smithy such asrectangular tray, and open Cylinder.
4. Ability to perform various basic House Wiring techniques such as connecting one lamp with one switch,
connecting two lamps with one switch, connecting a fluorescent tube, Series wiring, Go down wiring.
5. Ability to design and model various basic prototypes in the trade of Welding such as Lap joint, Lap Tee joint,
Edge joint, Butt joint and Corner joint.
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ENGINEERING WORKSHOP SYLLABUS
Course Code 22ES0ME01

Category Basic Sciences
Course Title ENGINEERING WORKSHOP
Year I YEAR
L T P D Credits
Scheme and Credits
0 1 3 0 2.5
Prerequisites Practical skill
Course Objectives:
 To Study of different hand-operated power tools, uses and their demonstration.

 To gain a good basic working knowledge required for the production of various engineering products.
 To provide hands on experience about use of different engineering materials, tools, equipment and processes
 those are common in the engineering field.
 To develop the right attitude, team working, precision and safety at work place.
 It explains the construction, function, use and application of different working tools, equipment and machines.
 To study commonly used carpentry joints.
 To have practical exposure to various welding and joining processes.
 Identify and use marking out tools, hand tools, measuring equipment and to work to prescribed tolerances.
Course Outcomes: At the end of the course, the student will be able to:
 Study and practice on machine tools and their operations
 Practice on manufacturing of components using workshop trades including pluming, fitting, carpentry,
foundry, house wiring and weldng.
 Identify and apply suitable tools for different trades of Engineering processes including drilling, material
removing, measuring and chiseling.
 Apply basic electrical engineering knowledge for house wiring practice.
1. TRADES FOR EXERCISES:

At least two exercises from each trade:
I. Carpentry – (T-Lap Joint, Dovetail Joint, Mortise & Tenon Joint)
II. Fitting – (V-Fit, Dovetail Fit & Semi-circular fit)
III. Tin-Smithy – (Square Tin, Rectangular Tray & Conical Funnel)
IV. Foundry – (Preparation of Green Sand Mould using Single Piece and Split Pattern)
V. Welding Practice – (Arc Welding & Gas Welding)
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VI. House-wiring – (Parallel & Series, Two-way Switch and Tube Light)
VII. Black Smithy – (Round to Square, Fan Hook and S-Hook)
2. TRADES FOR DEMONSTRATION & EXPOSURE:
Plumbing, Machine Shop, Metal Cutting (Water Plasma), Power tools in construction and Wood
Working
TEXT BOOKS:
1. Workshop Practice /B. L. Juneja / Cengage

2. Workshop Manual / K. Venugopal / Anuradha.
REFERENCE BOOKS:
1. Work shop Manual - P. Kannaiah/ K.L. Narayana/ Scitech

2. Workshop Manual / Venkat Reddy/ BSP
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INDEX
S.NO TRADE EXPERIMENTS Page No
Cross lap joint 19
1 CARPENTRY Dove tail lap joint 20
Tennon joint 21
L-shape fit 34
2 FITTING V-groove fit 35
Semi circular fit 36
Rectangular tray 41
3 TIN SMITHY Square elbow 42
Funnel 43
Flat square rod 50
4 BLACK SMITHY S-Hook 51
Hook bolt 52
Series connection
Parallel connection
5 HOUSE WIRING
One lamp controlled
by 2-way switch
Single piece pattern

6 FOUNDARY Dumb-Bell pattern
Stepped pattern
Lap joint
7 WELDING
V-Butt joint
8 POWERTOOLS
Connection of G.V.C
pipes
9 PLUMBING
Connection of P.V.C 91
pipes
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CARPENTRY
INTRODUCTION
Carpentry may be defined as the process of making wooden components. It starts from a marketable form
of wood and ends with finished products. It deals with the building work, furniture, cabinet making. etc. joinery,
i.e., preparation of joints is one of the important operations in all woodworks.
It deals with the specific work of carpenter like making different types of joints to form a finished product.
TIMBER
Timber is the name given to the wood obtained from well grown trees. The trees are cut, sawn into
various sizes to suit building purposes.
The word, „grain‟, as applied to wood, refers to the appearance or pattern of the wood on the cut surfaces.
The grain of the wood is a fibrous structure and to make it strong, the timber must be so cut, that the grains run
parallel to the length.
Wood suitable for construction and other engineering purposes is called timber. Woods in general are
divided into two broad categories: Soft woods and Hard woods.
Soft woods are obtained from conifers, kair, deodar, chir, walnut and seemal. Woods obtained from teak,
sal, oak, shisham, beach, ash mango, neem and babul are known as hard wood, but it is highly durable. Another
classification of woods is based on the name of the trees like teak, babul, shisham, neem, kair, chir, etc
Characteristics of Good Timber

The good timber must possess the following characteristics
a. It should have minimum moisture content, i.e., the timber should be well seasoned.
b. The grains of wood should be straight and long.
c. It must retain its straightness after seasoning.
d. It should produce near metallic sound on hammering.
e. It should be free from knots or cracks.
f. It should be of uniform color, throughout the part of the wood.
g. It should respond well to the finishing and polishing operations.
h. During driving the nails and screw, it should not split easily.
MARKING AND MEASURING TOOLS
Accurate marking and measurement is very essential in carpentry work, to produce parts to exact size. To
transfer dimensions onto the work; the following are the marking and measuring tools that are required in a
carpentry shop.
Steel rule and Steel tape

Steel rule is a simple measuring instrument consisting of a long, thin metal strip with a marked scale of
unit divisions. It is an important tool for linear measurement. Steel tape is used for large measurements, such as
marking on boards and checking the overall dimensions of the work.
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Figure : Steel rule and Steel tape
Marking gauge
It is a tool used to mark lines parallel to the edge of a wooden piece. It consists of a square wooden stem
with a sliding wooden stock (head) on it. On the stem is fitted a marking pin, made of steel. The stock is set at
any desired distance from the marking point and fixed in position by a screw. It must be ensured that the marking
pin projects through the stem, about 3mm and the end are sharp enough to make a very fine line. A mortise gauge
consists of two pins. In this, it is possible to adjust the distance between the pins, to draw two parallel lines on the
stock.
a. Marking gauge b. Mortise gauge

Figure : Marking gauges
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Try‐square
It is used for marking and testing the squareness and straightness of planed surfaces. It consists of
a steel blade, fitted in a cast iron stock. It is also used for checking the planed surfaces for flatness. Its size varies
from 150 to 300 mm, according to the length of the blade. It is less accurate when compared to the try‐square
used in the fitting shop.
Figure : Try square
Compass and divider

Compass and divider, are used for marking arcs and circles on the planed surfaces of the wood
Scriber or marking knife
It is used for marking on timber. It is made of steel having one end pointed and the other end formed into
a sharp cutting edge.
Bevel
It is used for laying‐out and checking angles. The blade of the bevel is adjustable and may beheld in place
by a thumb screw. After it is set to the desired angle, it can be used in much the same way as a try‐square. A
good way to set it to the required angle is to mark the angle on a surface and then adjust the blade to fit the angle.
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HOLDING TOOLS
Carpenter's vice
Figure 6 shows the carpenter's bench vice, used as a work holding device in a carpenter shop. Its one jaw
is fixed to the side of the table while the other is movable by means of a screw and a handle. The Carpenter's vice
jaws are lined with hard wooden' faces
Figure 2.8 shows a bar cramp. It is made of steel bar of T‐section, with malleable iron fittingsand a steel
screw. It is used for holding wide works such as frames or tops.
Figure : bar cramp
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PLANING TOOLS
Planing is the operation used to produce flat surfaces on wood. A plane is a hand tool used for this
purpose. The cutting blade used in a plane is very similar to a chisel. The blade of a plane is fitted in a wooden or
metallic block, at an angle.
Jack plane
It is the most commonly used general purpose plane. It is about 35 cm long. The cutting iron (blade)
should have a cutting edge of slight curvature. It is used for quick removal of material on rough work and is also
used in oblique planning
Smoothing plane
It is used for finishing work and hence, the blade should have a straight cutting edge. It is about 20 to 25
cm long. Being short, it can follow even the slight depressions in the stock, better than the jack plane. It is used
after using the jack plane
Rebate plane.
It is used for making a rebate. A rebate is a recess along the edge of a piece of wood, which is generally
used for positioning glass in frames and doors
Plough plane
It is used to cut grooves, which are used to fix panels in a door. Figure 9 shows the various types of planes
mentioned above
Figure : Types of planes
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CUTTING TOOLS
Saws
A saw is used to cut wood into pieces. There are different types of saws, designed to suit different
purposes. A saw is specified by the length of its toothed edge.
Cross‐cut or hand saw

It is used to cut across the grains of the stock. The teeth are so set that the saw kerf will be wider than the
blade thickness. This allows the blade to move freely in the cut, withoutsticking
Rip saw
It is used for cutting the stock along the grains. The cutting edge of this saw makes a steeper angle, i.e.,
about 60° whereas that of crosscut saw makes an angle of 45° with the surface of the stock.
Tenon saw
It is used for cutting the stock either along or across the grains. It is used for cutting tenons and in fine
cabinet work. However, it is used for small and thin cuts. The blade of this saw is very thin and so it is stiffened
with a thick back steel strip. Hence, this is sometimes called as back‐saw. In this, the teeth are shaped like those
of cross‐cut saw.
Compass saw
It has a narrow, longer and stronger tapering blade, which is used for heavy works (Fig. 1.13). It is mostly
used in radius cutting. The blade of this saw is fitted with an open type wooden handle.
Figure : Types of saws
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Chisels
Chisels are used for cutting and shaping wood accurately. Wood chisels are made in various blade widths,
ranging from 3 to 50 mm. They are also made in different blade lengths. Most of the wood chisels are made into
tang type, having a steel shank which fits inside the handle. These are made offorged steel or tool steel blades.
Firmer chisel
The word 'firmer' means 'stronger' and hence firmer chisel is stronger than other chisels. It is a general
purpose chisel and is used either by hand pressure or by a mallet. The blade of a firmer chisel is flat, as shown in
Figure 12 a.
Dovetail chisel
It has a blade with a beveled back, as shown in Figure, due to which it can enter sharp comers for finishing,
as in dovetail joints.
Mortise chisel
It is used for cutting mortises and chipping inside holes, etc. The cross‐section of the mortise chisel is
proportioned to withstand heavy blows during mortising. Further, the cross‐section is made stronger near the
shank.
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DRILLING AND BORING TOOLS
Carpenter’s brace
It is used for rotating auger bits, twist drills, etc., to produce holes in wood. In some designs, braces are
made with ratchet device. With this, holes may be made in a corner where complete revolution of the handle
cannot be made. The size of a brace is determined by its sweep.
Auger bit
It is the most common tool used for making holes in wood. During drilling, the lead screw of the bit
guides into the wood, necessitating only moderate pressure on the brace. The helical flutes on the surface carry
the chips to the outer surface.
Hand drill
Carpenter's brace is used to make relatively large size holes; whereas hand drill is used for drilling small
holes. A straight shank drill is used with this tool. It is small, light in weight and may be conveniently used than
the brace. The drill bit is clamped in the chuck at its end and is rotated by a handle attached to gear and pinion
arrangement.
Gimlet
It has cutting edges like a twist drill. It is used for drilling large diameter holes with the handpressure
MISCELLANEOUS TOOLS
Mallet
It is used to drive the chisel, when considerable force is to be applied, which may be the case in making deep
rough cuts. Steel hammer should not be used for the purpose, as it may damage the chisel handle. Further, for
better control, it is better to apply a series of light taps with the mallet rather than a heavy single blow.
Pincer
It is made of two forged steel arms with a hinged joint and is used for pulling‐out small nails from wood.
The inner faces of the pincer jaws are beveled and the outer faces are plain. The end of one arm has a ball and the
other has a claw. The beveled jaws and the claw are used for pulling out small nails, pins and screws from the
wood.
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Claw hammer
It has a striking flat face at one end and the claw at the other, as shown in figure. The face is used to drive nails
into wood and for other striking purposes and the claw for extracting relatively large nails out of wood. It is made
of cast steel and weighs from 0.25 kg to 0.75 kg.
Screw driver
It is used for driving screws into wood or unscrewing them. The screw driver of a carpenter is different
from the other common types, as shown in figure. The length of a screw driver is determined by the length of the
blade. As the length of the blade increases, the width and thickness of the tip also increase.
Wood rasp file
It is a finishing tool used to make the wood surface smooth, remove sharp edges, finish fillets and other
interior surfaces. Sharp cutting teeth are provided on its surface for the purpose. This file is exclusively used in
wood work.
Bradawl
It is a hand operated tool, used to bore small holes for starting a screw or large nail.
MECH EWS 17
SAFE PRACTICE
The following are some of the safe and correct work practices in carpentry shop, with respect tothe tools used
1. Tools that are not being used should always be kept at their proper places.
2. Make sure that your hands are not in front of sharp edged tools while you are using them.
3. Use only sharp tools. A dull tool requires excessive pressure, causing the tool to slip.
4. Wooden pieces with nails, should never be allowed to remain on the floor.
5. Be careful when you are using your thumb as a guide in cross‐cutting and ripping.
6. Test the sharpness of the cutting edge of chisel on wood or paper, but not on your hand.
7. Never chisel towards any part of the body.
8. Do not use chisels where nails are present. Do not use chisel as a screw driver.
9. Do not use a saw with a loose handle.
10. Always use triangular file for sharpening the teeth.
11. Do not use a saw on metallic substances.
MECH EWS 18
EXPERIMENT 01
Aim: To make Cross Lap joint as per dimensions
Material Required: Teak wood 35 mm x 50 mm x 300 mm
Tools Required:
Carpenter's vice, steel rule, jack plane, try‐square, marking gauge, chisel, cross‐cut saw, tenon saw,
scriber and mallet
Sequence of operations:
The given wood is checked to ensure its correct size.
1. The wood is firmly clamped in the carpenter's vice and any two adjacent faces are planed bythe jack plane and
the two faces are checked for squareness with the try square.
2. Marking gauge is set and lines are drawn to required size, to mark the thickness and width of the model
respectively.
3. The excess material is first chiseled out with firmer chisel and then planed to correct size.
4. The mating dimensions of the parts X and Yare then marked using scale and markinggauge.
Using the cross‐cut saw, the portions to be removed are cut in both the pieces, followed by chiseling and also the
parts X and Y are separated by cross‐cutting, using the tenon saw
5. The ends of both the parts are chiseled to the exact lengths.
6. A fine finishing is given to the parts, if required so that, proper fitting is obtained.
The parts are fitted to obtain a slightly tight joint.
Result The Lap joint is thus made by following the above sequence of operations.
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EXPERIMENT 02
Aim: To make dove tail joint as per dimensions
Material Required: Teak wood 35 x 50 x 300 mm
Tools Required:
Carpenter's vice, steel rule, jack plane, try‐square, marking gauge, chisel, cross‐cut saw,tenon saw, scriber and
mallet.
1. The wood is firmly clamped in the carpenter's vice and any two adjacent faces are planed by thejack plane and
2. Marking gauge is set and lines are drawn to required size, to mark the thickness and width ofthe model
respectively.
4. The mating dimensions of the parts X and Yare then marked using scale and markinggauge
5. Using the cross‐cut saw, the portions to be removed are cut in both the pieces, followed bychiseling and also
the parts X and Y are separated by cross‐cutting, using the tenon saw
8. The parts are fitted to obtain a slightly tight joint.
Result The dove tail joint is thus made by following the above sequence of operations.
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EXPERIMENT 03
Aim: To make Tenon joint as per dimensions
Material Required: Teak wood 35 x 50 x 300 mm
Tools Required:
Carpenter's vice, steel rule, jack plane, try‐square, marking gauge, chisel, cross‐cut saw, tenon saw,scriber and
mallet.
1..The wood is firmly clamped in the carpenter's vice and any two adjacent faces are planed by thejack plane and
2. Marking gauge is set and lines are drawn to required size, to mark the thickness and width ofthe model
respectively.
4. The mating dimensions of the parts X and Yare then marked using scale and marking gauge
5. Using the cross‐cut saw, the portions to be removed are cut in both the pieces, followed bychiseling and also
the parts X and Y are separated by cross‐cutting, using the tenon saw
8. The parts are fitted to obtain a slightly tight joint.
Result The tenon joint is thus made by following the above sequence of operations.
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VIVA- VOICE
1: Name the common carpentry tools?
Ans: (i) Steel rule. ii)Try square. iii) Rip saw iv)Firmer chisel v)Jack plane vi)Rasp cut filev ii)Hammer
viii) Wooden mallet
2. What is the use for firmer chisel?
Ans:To make groove
3. Name the carpentry process?.
(i) Marking ii)Sawing iii)Planning iv) Chiseling v)Grooving
MECH EWS 22
FITTING SHOP
INTRODUCTION
Machine tools are capable of producing work at a faster rate, but, there are occasions when components are
processed at the bench. Sometimes, it becomes necessary to replace or repair component which must be fit
accurately with another component on reassembly. This involves a certain amount of hand fitting. The assembly
of machine tools, jigs, gauges, etc, involves certain amount of bench work. The accuracy of work done depends
upon the experience and skill of the fitter. The term „bench work‟ refers to the production of components by
hand on the bench, where as fitting deals which the assembly of mating parts, through removal of metal, to
obtain the required fit. Both the bench work and fitting requires the use of number of simple hand tools and
considerable manual efforts. The operations in the above works consist of filing, chipping, scraping, sawing
drilling, and tapping.
HOLDING TOOLS
Bench vice
The bench vice is a work holding device. It is the most commonly used vice in a fitting shop. The bench
vice is shown in Figure 1
Figure : Bench Vice
It is fixed to the bench with bolts and nuts. The vice body consists of two main parts, fixed jaw and
movable jaw. When the vice handle is turned in a clockwise direction, the sliding jaw forces the work against the
fixed jaw. Jaw plates are made of hardened steel. Serrations on the jaws ensure a good grip. Jaw caps made of
soft material are used to protect finished surfaces, gripped in the vice. The size of the vice is specified by the
length of the jaws. The vice body is made of cast Iron which is strong in compression, weak in tension and so
fractures under shocks and therefore should never be hammered.
MECH EWS 23
V- block
V- block is rectangular or square block with a V-groove on one or both sides opposite to each other. The
angle of the „V‟ is usually 900. V-block with a clamp is used to hold cylindrical work securely, during layout of
measurement, for measuring operations or for drilling for this the bar is faced longitudinally in the V Groove
and the screw of V -clamp is tightened. This grip the rod is firm with its axis parallel to the axis of the v groove.
C- Clamp
This is used to hold work against an angle plate or V-block or any other surface, when gripping is
required. Its fixed jaw is shaped like English alphabet „C‟ and the movable jaw is round in shape and directly
fitted to the threaded screw at the end. The working principle of this clamp is the same as that of the bench vice.
Figure : V‐block Figure : C‐clamp
MARKING AND MEASURING TOOLS
Surface plate
The surface plate is machined to fine limits and is used for testing the flatness of the work piece. It is also
used for marking out small box and is more precious than the marking table. The degree of the finished depends
upon whether it is designed for bench work in a fitting shop or for using in an inspection room; the surface plate
is made of Cast Iron, hardened Steel or Granite stone. It is specified by length, width, height and grade. Handles
are provided on two opposite sides, to carry it while shifting from one place to another.
Figure : Surface plate Figure : Angle pla
MECH EWS 24
Trysquare
It is measuring and marking tool for 900 angle .In practice, it is used for checking the squareness of many
types of small works when extreme accuracy is not required .The blade of the Try square is made of
hardened steel and the stock of cast Iron or steel. The size of the Try square is specified by the length of the
blade.
Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on metal work pieces. It is made ofhardened
and tempered High Carbon Steel. The Tip of the scriber is generally ground at 120 to
150. It is generally available in lengths, ranging from 125mm to 250mm .It has two pointed endsthe bent end is
used for marking lines where the straight end cannot reach.
Odd leg Caliper

This is also called „Jenny Caliper‟ or Hermaphrodite. This is used for marking parallel liners from a
finished edge and also for locating the center of round bars; it has one leg pointed like a divider and the other leg
bent like a caliper. It is specified by the length of the leg up to the hingepoint.
Divider
It is basically similar to the calipers except that its legs are kept straight and pointed at the measuring edge.
This is used for marking circles, arcs laying out perpendicular lines, by setting lines. It is made of case hardened
mild steel or hardened and tempered low carbon steel. Its sizeis specified by the length of the leg.
Figure : Odd leg caliper and divider
MECH EWS 25
Trammel:
Trammel is used for drawing large circles or arcs.
Punches
These are used for making indentations on the scribed lines, to make them visible clearly. These are made
of high carbon steel. A punch is specified by its length and diameter (say as 150‟ 12.5mm). It consists of a
cylindrical knurled body, which is plain for some length at the top of it. At the other end, it is ground to a point.
The tapered point of the punch is hardened over a length of 20 to 30mm.
Dot punch is used to lightly indent along the layout lines, to locate center of holes and to provide a small
center mark for divider point, etc. for this purpose, the punch is ground to a conical point having 60° included
angle.
Center punch is similar to the dot punch, except that it is ground to a conical point having 90° included
angle. It is used to mark the location of the holes to be drilled.
Figure : Punches
Calipers
They are indirect measuring tools used to measure or transfer linear dimensions. These are used with the
help of a steel Rule to check inside and outside measurements. These are made of Case hardened mild steel or
hardened and tempered low carbon steel. While using, but the legs of the caliper are set against the surface of the
work, whether inside or outside and the distance between the legs is measured with the help of a scale and the
same can be transferred to another desired place. These are specified by the length of the leg. In the case of
outside caliper, the legs are bentinwards and in the case of inside caliper, the legs bent outwards.
MECH EWS 26
CUTTING TOOLS
Hack Saw
The Hack Saw is used for cutting metal by hand. It consists of a frame, which holds a thin blade, firmly in
position. Hacksaw blade is specified by the number of teeth for centimeter. Hacksaw blades have a number of
teeth ranging from 5 to 15 per centimeter (cm). Blades having lesser number of teeth per cm are used for cutting
soft materials like aluminum, brass and bronze. Blades having larger number of teeth per centimeter are used for
cutting hard materials like steel and cast Iron. Hacksaw blades are classified as (i) All hard and (ii) flexible type.
The all hard blades are made of H.S.S, hardened and tempered throughout to retain their cutting edges longer.
These are used to cut hard metals. These blades are hard and brittle and can break easily by twisting and forcing
them into the work while sawing. Flexible blades are made of H.S.S or low alloy steel but only the teeth are
hardened and the rest of the blade is soft and flexible. These are suitable for use by un‐skilled or semi‐skilled
persons.
Figure : Hacksaw frame with blade
Chisels
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from0.9% to 1.0%
carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened andtempered to produce a tough
shank and hard cutting edge. Annealing relieves the internalstresses in a metal. The cutting angle of the chisel
for general purpose is about 60°.
Figure : Flat chisel
MECH EWS 27
Twist Drill
Twist drills are used for making holes. These are made of High speed steel. Both straight and taper shank
twist drills are used. The parallel shank twist drill can be held in an ordinary self – centering drill check. The
tapper shank twist drill fits into a corresponding tapered bore provided in the drilling machine spindle.
Figure : Twist drills
Taps and Tap wrenches

A tap is a hardened and steel tool, used for cutting internal thread in a drill hole. Hand Taps are usually
supplied in sets of three in each diameter and thread size. Each set consists of a tapper tap, intermediate tap
and plug or bottoming tap. Taps are made of high carbon steel or high speedsteel.
Figure : Taps and tap wrench

MECH EWS 28
Dies and die‐holders
Dies are the cutting tools used for making external thread. Dies are made either
solid or split type. They are fixed in a die stock for holding and adjusting the die gap. They aremade of Steel or
High Carbon Steel
Figure : Dies and die holder
Files
Filing is one of the methods of removing small amounts of material from the surface of a metal part. A file
is hardened steel too, having small parallel rows of cutting edges or teeth on its surfaces. On the faces, the teeth
are usually diagonal to the edge. One end of the file is shaped to fit into a wooden handle. The figure shows
various parts of a hand file. The hand file is parallel in width and tapering slightly in thickness, towards the tip.
It is provided with double cut teeth. On the faces, single cut on one edge and no teeth on the other edge, which is
known as a safe edge
Files are classified according to their shape, cutting teeth and pitch or grade of the teeth. Thefigure shows the
various types of files based on their shape.
MECH EWS 29
Figure : Types of files

MECH EWS 30
MISCELLANEOUS TOOLS
File card
It is a metal brush, used for cleaning the files, to free them from filings, clogged in‐betweenthe teeth.
Figure : File card
Spirit level
It is used to check the leveling of machines.
Ball‐ Peen Hammer
Ball‐ Peen Hammers are named, depending upon their shape and material and specified bytheir weight. A
ball peen hammer has a flat face which is used for general work and a ball end, particularly used for riveting.
Figure : Ball peen hammer

Cross‐Peen Hammer
It is similar to ball peen hammer, except the shape of the peen. This is used for chipping, riveting, bending
and stretching metals and hammering inside the curves andshoulders
Straight peen hammer
This is similar to cross peen hammer, but its peen is in‐line with the hammer handle. It is used for swaging,
riveting in restricted places and stretching metals
MECH EWS 31
Figure : Cross peen hammer Figure : Straight peen hammer
Screw driver
A screw driver is designed to turn screws. The blade is made of steel and is available in different lengths and
diameters. The grinding of the tip to the correct shape is very important. A star screw driver is specially designed
to fit the head of star screws. The end ofthe blade is fluted instead of flattened. The screw driver is specified by
the length of the metal part from handle to the tip
Figure : Screw drivers
Spanners
A spanner or wrench is a tool for turning nuts and bolts. It is usually made of forged steel. There are many
kinds of spanners. They are named according to the application. The size ofthe spanner denotes the size of the
bolt on which it can work
Figure : Spanners
MECH EWS 32
SAFE PRACTICE
The following are some of the safe and correct work practices in bench work and fitting shop,with respect to the
tools used
1. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are safer to use than slippery
tools.
2. Do not carry sharp tools on pockets.
3. Wear leather shoes and not sandals.
4. Don‟t wear loose clothes.
5. Do no keep working tools at the edge of the table.
6. Position the work piece such that the cut to be made is close to the vice. This practiceprevents springing, saw
breakage and personal injury.
7. Apply force only on the forward (cutting) stroke and relieve the force on the return stroke while sawing and
filing.
8. Do not hold the work piece in hand while cutting.
9. Use the file with a properly fitted tight handle.
10. After filing, remove the burrs from the edges of the work, to prevent cuts to the fingers.
11. Do not use vice as an anvil
MECH EWS 33
EXPERIMENT 01
Aim: To make a straight fit as per the given dimensions
Materials Required: M.S flat of 40 x 40 x 5 mm
Tools Required: Bench vice, set of Files, Steel rule, Try‐square, Vernier caliper, Vernier
heightgauge, Hack saw, Ball‐peen hammer, Scriber, Dot punch, Surface plate, Angle plate and
Anvil.
1. The dimensions of the given piece are checked with the steel rule.
2. The job is fixed rigidly in a bench vice and the two adjacent sides are filed, using the
roughflat file first and then the smooth flat file such that, the two sides are at right angle.
3. The right angle of the two adjacent sides is checked with the try‐square.
4. Chalk is then applied on the surface of the work piece.
5. The given dimensions are marked by scribing two lines, with reference to the above
twodatum sides by using Vernier height gauge, Angle plate and Surface plate.
6. Using the dot punch, dots are punched along the above scribed lines.
7. The two sides are then filed, by fitting the job in the bench vice; followed by checking
theflatness of the surfaces.
As the material removal through filing is relatively less, filing is done instead of sawing.
Result:The straight fit joint is thus obtained by filing, as discussed above.
MECH EWS 34
EXPERIMENT 02
Aim: To make V‐ fit from the given two MS plates
Anvil.
Sequence of operations
1. The burrs in the pieces are removed and the dimensions are checked with steel rule.
2. Make both pieces surface levels and right angles by fixing in the Vice, use Files for
removingmaterial to get level.
3. With the help of Try square check the right angles and surface levels.
4. Using Surface plate and Angle plate mark the given two metal pieces as per drawing
withVernier height gauge.
5. Punch the scribed lines with dot punch and hammer keeping on the Anvil. Punch
topunch give 5 mm gap.
6. Cut excess material wherever necessary with Hacksaw frame with blade.
7. The corners and flat surfaces are filed by using square/flat and triangular file to get the
sharpcorners.
8. Dimensions are checked by vernier caliper and match the two pieces. Any defect
noticed,are rectified by filing with a smooth file.
9. Care is taken to see that the punched dots are not crossed, which is indicated by the half
ofthe punch dots left on the pieces.
Result
The required V‐ fitting is thus obtained, by following the stages, as described above.
MECH EWS 35
EXPERIMENT 3
Aim: To make semi circular fit from the given two MS plates
Anvil.
Sequence of operations
1. The burrs in the pieces are removed and the dimensions are checked with steel rule.
2. Make both pieces surface levels and right angles by fixing in the Vice, use Files for
removingmaterial to get level.
3. With the help of Try square check the right angles and surface levels.
4. Using Surface plate and Angle plate mark the given two metal pieces as per drawing with
Vernierheight gauge.
5. Punch the scribed lines with dot punch and hammer keeping on the Anvil. Punch to punch give
5mm gap.
6. Cut excess material wherever necessary with Hacksaw frame with blade.
7. The corners and flat surfaces are filed by using square/flat and triangular file to get
thesharp corners.
8. Dimensions are checked by vernier caliper and match the two pieces. Any defect
noticed,are rectified by filing with a smooth file.
9. Care is taken to see that the punched dots are not crossed, which is indicated by the half of
thepunch dots left on the pieces.
Result
The required semi circular fit is thus obtained, by following the stages, as described above.
MECH EWS 36
VIVA-VOICE
What is the name of vice used in fitting shop? Ans:

Bench vice
Name the different files?
ANS: (i) Flat file (ii) Square file (iii) Round file
(iv) Triangular file (v) Half round file
Which tools are used in fitting shop?
Ans: (i) Steel rule (ii) Try square (iii) Vernier caliper
(iv) Scriber (v) Center punch (vi) Hammer
(vii) Hacksaw frame with blade (viii) Rough file & Smooth file
What is the use of center punch?

Ans: Center punch used in a bench work for marking out work, locating center etc.
What is the use of try square?

Ans:For measuring 90 Degree work
MECH EWS 37
TIN SMITHY
INTRODUCTION:
The metal plank having less than 2 mm thick is called sheet metal. Sheet metal work deals with the
production of components in wide variety of shapes and sizes from sheet metal with aid of tools or machines
metals used in sheet metal work variety of metal shop the characteristics and used of some of the important
metals used in sheet metal work are described below.
1. Galvanized iron: It is a sheet of soft steel, which is coated with zinc. Zinc resists corrosion
and improves the appearance of metal galvanized iron is one of the least expensive metals
and is used for making pans, buckets, ducts, gutters, tanks, boxes etc.
2. Black iron: It is uncoated sheet of metal with bluish-black appearance. It corrodes rapidly
is not extensively used due to difficulties of soldering the block iron sheet are used for
theparts that are to be painted.
3. Tin plate: Tin plate is an iron or steel coated with pure tin. It has very bright
silverappearance and is used for food containers, cans and pans.
4. Stainless Steels: It is an alloy steel possessing corrosion resistance. General type stainless
steel contains 18 percent chromium and 8 percent nickel. This steel is commonly known as
18-8 stainless steel. These are available various sizes and thickness. It is widely used for
food containers, dairy equipment.
5. Copper: It has reddish color and posses good malleability, ductility and resistance
toatmospheric corrosion.
6. Aluminium: Sheet aluminium is never pure aluminium and it is always allowed with
smallquantities of copper silicon, magnesium and iron.
TOOLS AND EQUIPMENT
Some of the tools used in fitting are also used in sheet metal work.Certain additional
toolsused by sheet metal worker are described.
Snips: Hand shears or snips are used to cut sheet metal. Although there are many types,
thesheet metal workers generally use straight snips and curved snips.
Straight snips: Straight snips have straight blades and are used for cutting along the
straightlines and for trimming edges.
Curved snips: Curved snips has a curved blade and used for cutting circles and irregular shapes.
MECH EWS 38
Bench shears: Bench shear is used for cutting thicker sheets. It is the lower fixed blade is firmly secured by
bracket at the bottom. The movable blade is pivoted at the rear end, the hand operating lever is attached to the
front end of movable blade a link mechanism.
Stakes: Stakes are made of steel and forged in a variety of shapes and sizes. Its working face is machined and
polished to facilitate various operations such as bending, seaming or forming.
The following types of stakes are most generally used.
Double seaming: These stakes has two horns and it is used to make double seam for vessels. Blow horn: These
stakes has two horn tapering horns and it is used to forming or seaming funnels. Break horn: These stakes has a
square tapered horn on one side and a round tapered horn on opposite side. It is used for shaping round and
square surfaces, bending edges and making corners.
Conductor stake: These stakes has two cylindrical horns having different diameters. It is used for forming
pipes and cylindrical pieces.
Funnel stake: It is used for forming conical shapes and for making wire rings.
Hatchet stake: It has a horizontal sharp straight edge and can be used for making straight, Sharp bends and for
folding and bending edges.
Hand hammers and mallets: The sheet metal worker uses a wide variety of hammers and Mallet for forming
shapes by different operation. The most commonly used hammers are follows.
Straight –peen hammer: It has a peen end similar to its bottom size round shape and its top side is straight
point. Square, slightly curved face and its peen is tapered it is used for riveting.
Cross peen hammers :It has a square, flat face and its tapered on one side it is used for setting down the edges
for making a double seam
MECH EWS 39
Mallet: Mallet is generally made of wood or plastic. It is used whenever slight blows are required.
Wooden mallet do not damage the surface.
Wire Gauge: The thickness of sheet metal is referred in numbers known as standard wire gauge (SWG).
The gaps in the circumference of the gauge are used to check the gauge number as shown below.
Sheet Metal Joints: Various types of joints are used in sheet metal work to suit the varying requirements.
Some commonly used sheet metal joints and folded edges are shown below. These are self secured
joints, formed by joining together two pieces of sheet metal and using the metal itself to form the joint.
SAFETY PRECAUTIONS
Never carry tools in pockets.

 Do not try to hold the sheets with bare hands.
 Do not remove any guards on squaring shear.
 Care should be exercised when working on squaring shears. Be sure that the fingers are away
from the shearing blade.
 Never use a soldering iron a loose handle.
 Never touch a soldering iron to see its hotness. The safest method is to touch the iron tosolder.
The melting of solder indicates the correct temperature.
 Be careful when cutting out a pattern. Remove scrap metal to avoid injuries
MECH EWS 40
EXPERIMENT 01
Aim: To prepare a rectangular tray from the sheet metal as per the given dimensions
Materials required: GI sheet of 165 mm x 150 mm 32 gauage
Tools required:
1. Straight snip 2. Curved snip 3. Ball peen hammer 4. mallet
5. Steel rule 6. Tool bench 7. Protractor 8. try square
9.Scriber 10. Hole punch 11. set punch 12. stand wire gauge
Procedure
1. The given size of the sheet metal sheet cut and checked for dimensions
2. Prepare a template as per the given dimensions directly on the sheet metal only
3. Cut according to the development of the surface i.e template, with the help of snipnotching operations
4. The sheet metal is bent along the marked lines by striking with the mallet on properstake
5. The edge of the sheet metal is folded to strengthen the edge and eliminate sharpedges.
6. The material which is remained is removed by using filing using smooth file
7. Finally seaming operation is completed to obtain the given shape of the job
8. Then rectangular tray is obtained
Result: As per the given dimension rectangular tray is prepared.
MECH EWS 41
EXPERIMENT 02
Aim: To prepare a square elbow from the sheet metal as per the given dimensions
Materials required: GI sheet of 125 mm x 120 mm
Tools required:
1. Straight snip 2. Curved snip 3. Ball peen hammer 4. mallet
5. Steel rule 6. Tool bench 7. Protractor 8. try square
9.Scriber 10. Hole punch 11. set punch 12. stand wire gauge
Procedure
1. The given size of the sheet metal sheet cut and checked for dimensions
2. Prepare a template as per the given dimensions directly on the sheet metal only
3. Cut according to the development of the surface i.e template, with the help of snipnotching
operations
4. The sheet metal is bent along the marked lines by striking with the mallet on proper stake
5. The edge of the sheet metal is folded to strengthen the edge and eliminate sharp edges
6. The material which is remained is removed by using filing using smooth file
7. Finally seaming operation is completed to obtain the given shape of the job
Then square elbow is obtained.
Result: As per the given dimension square elbow is prepared
MECH EWS 42
EXPERIMENT 3
Aim: To make a funnel from the given sheet metal.

Tools required
Steel rule, Mallet, Scriber, Divider, Protractor, Snips, Stakes, Ball peen hammer, Solder
Procedure
1. The size of the given sheet is checked for its dimension using steel rule.
2. The required development of surface is being made on the white paper which is
overlapped on the sheet metal.
3. The marking is done on the sheet metal as per the development being done on the paper.
4. Now using straight snips, unwanted material are removed.
5. Now fold and bend the workpiece to make the funnel shape and joint is made on the
workpieces.
6. Then using a groove, a locked grooved joint is made for about 5mm. also; hemming is donein the
bottom of the funnel.
7. In between top face and bottom face, a butt joint is made using a solder.
8. Finally, trimming and finishing operations are carried out.
Result: Thus desired funnel is made from the given sheet metal.
MECH EWS 43
BLACKSMITHY
Introduction:
It is one of the manufacturing processes in which the metals are processed to get the desired size
and shape by applying mechanical force or by heating the metal and then applying smaller amount of force.
Black smithy or hand forging is an ancient trade. It is employed only for relatively small components.
Nowadays machines are also used in forging the components wherehuge force is to be applied.
Tools used in smithy shop:
Supporting tools

Striking tools

Holding tools

Cutting tools

Shaping and finishing tools
Forging is one of the oldest metal working processes. It is defined as the shaping of a heated metal by
hammering and pressing .In forging; metals are made plastic by heating them and deformed by hammering,
while they are hot.
This process is usually carried at above the recrystallisation temperature. Therefore it is regarded as hot
working. It is also called as Black Smithy.
Forge or Hearth: - The forge or hearth is needed for heating metals .In this forges, metals are heated to
plastic state for hammering them into desired shape.
Anvil: The anvil is used for supporting the work while hammering they are made in different forms to provide the
means for other forging operations. The usual form of anvil used in hand forging weighs up to 25 to 250 kgs. It has
a round hole for bending rods and a square hole for holding square shanks of various tools such as swages, fullers
etc.
The body is made of mild steel and a strip of high carbon steel about20 mm thick is welded to its to provide hard face.
Beak is used for bending metal to round shapes.
MECH EWS 44
Swage block: -The swage block is generally made of cast iron or cast steel. It has grooves on faces and holes in the body.
It is used as a support while forming different shapes and punching holes. It can also be used for finishing round, square
and hexagonal forms.
Sledgehammer: - The sledgehammers are heavy hammers used by smith helper. The various forms of
sledgehammers weigh 3 to 8 kgs. The sledgehammer is specified by its weight
Swages:-Swages are used for reducing and finishing the round square or hexagonal shapes. The top swage is
provided with handle and the bottom swage with square shank, which is held in hardie hole
Fuller: -Fullers are used in pairs for necking or growing operations. These are made in various shape and
sizes. The bottom fuller has square shank to fit in the hardie hole and top one is provided with handle
Flatters: -Flatters are used to obtain and smooth and finished flat surfaces. These are made of toolsteel with flat faces
Tongs:-The metal to be forged must be held securely, while it is being shaped. A pair of tongs of suitable size and shape
must be used for the purpose. They are made of mild steel and sizes vary from 40cmto 60cm in length and 6mm to 55mm
opening.
MECH EWS 45
Forging temperature of metals:
Mild steel 750-1300c
Wrought Iron 900-1300c
Medium carbon steel 750-1250c
High carbon &alloy steel 800-1150c
Forging operations:-
Drawing: -Drawing is the process of stretching the stock while reducing its cross section.
Upsetting:-It is the process of increasing the area of cross section
MECH EWS 46
Fullering: -Fullers are used for necking down a piece of work.
Flattening: These are used for finishing flat surfaces.
Swaging : These are used to reduce and finish to round or hexagonal form
MECH EWS 47
Bending: Bending of bars, flats etc., is done to produce different types of bent shapes such asangles, circles, ovals etc.
Twisting: It is also one of form of bending. It is done to increasing the rigidity of the work piece.
Cutting: Chisels are used to cut metals, either in hot or cold state.
Cutting Tools: It is used for cutting and necking metals prior to breaking. Two types
ofchisel normally used
(i) Cold chisel
(ii) Hot Chisel
Cold Chisel: It is made up of tool steel with a cutting angle of about 60o and its edge is hardened and tempered.
Hot Chisel: It is made up of low carbon steel and has a cutting angle of 300not require hardening.
Its edge does
MECH EWS 48
Safety precautions
1. The fire should be lightened in the hearth very carefully.
2. There should be no leakage of fuel from pipes and pipe joints.
3. All the exhaust gases and smoke should go to the chimney.
4. Hold the hot work piece downwards close to the ground,

while transferring from furnace to anvil to minimize danger
of burnsor any hazardous incident.
5. Never handle the tongs and hammer while working.
6. Never wear sliky cloths in forging shop while working.

Ensure the hammers are fitted with tight and wedged handles
MECH EWS 49
EXPERIMENT 01
Aim: To prepare a flat square rod from a given rod
Material Required: M S rod 12 mm dia x 250 mm length
Tools Required:
Smith forge, swage block, round hollow tong, shovel, hack saw blade, anvil,
sledgehammer, flater.
Procedure:
1. 12mm M.S bar is cut with hack saw blade has per required length.
2. Heat the rod sufficiently up to red hot condition in order to forge the bar.
3. One end of the bar is flattened by hammering against the end of the
bushplaced directly over the anvil through which stock is placed
4. Repeat the same for other end
5. Shape of the rod is made according to the given dimension and sized
byhammering carefully and also uniformly
6. Quench the bar to bring it to room temperature
Precautions
1. Avoid excess heating of rod

2. Care must be taken while using sledge hammer
3. Use of shoes, apron and gloves are most essential
Result Flat square rod from a given round rod is prepared.
MECH EWS 50
EXPERIMENT 02
Aim: To prepare a S- Hook from a given rod
Material Required: M S rod 12 mm dia x 250 mm length
Tools Required:
Smith forge, swage block, round hollow tong, shovel, hack saw blade, anvil,
sledgehammer, flater.
Procedure:
1. 12mm M.S bar is cut with hack saw blade has per required length.
2. Heat the rod sufficiently up to red hot condition in order to forge the bar.
3. One end of the bar is rounded in S-shape by hammering against the end of
thebush placed directly over the anvil through which stock is placed
4. Repeat the same for other end
5. Shape of the rod is made according to the given dimension and sized
byhammering carefully and also uniformly
6. Quench the bar to bring it to room temperature
Precautions
1. Avoid excess heating of rod
2. Care must be taken while using sledge hammer
3. Use of shoes, apron and gloves are most essential
Result: S- Hook from a given round rod is prepared
MECH EWS 51
EXPERIMENT NO:03
AIM: To prepare hook bolt from a given round rod.
MATERIAL REQUIRED: M.S rod 12mm dia X 250mm length
TOOLS REQUIRED:
1. Smith forge 2. Anvil
3. Swage block 4. Sledge hammer
5. Round hallow tong 6. Rectangular or hollow tong
7. Shovel 8. Flatter
9. Hack saw frame with blade
PROCEDURE:
1.12mm MS bar is cut with hack saw blade as per required length,
2. Sufficient heating up to i.e red hot condition is to be done to the bar in forge
3. One end of the bar is flattened by hammering against the end of a bush, placed directly
overthe hardie hole in the anvil through which the stock is placed
3. Repeat the same for the other end
4. Shape of the rod is made according to the given dimensions and size by hammering
carefullyand also uniformly.
5. Quench the bar to bring it to room temperature.
PRECAUTIONS:
1. Avoid excess heating of the rod.
2. Care must be taken while using the sledge hammer.
3. Use of shoes, apron and gloves are must essential
MECH EWS 52
VIVA- VOICE
1. Name the types of furnace?

Ans: Open fire & Stock fire furnace
2.Name the tools used in smithy shop?
Ans:
(i) Anvil
(ii) Swage block
(iii) Sledge hammer
(iv) Flat tongs
3. Why furnace is used in our workshop? Ans: To heat the job to set the required shape
Which type of furnace is used in our

workshop?
Ans: Open fire furnace
4. What is use of anvil & swage block?

Ans: Anvil for the support the job. Swage block is used for squaring, sizing, bending& forming operation
MECH EWS 53
HOUSE WIRING
Introduction: Electrical wiring is defined as a system of electrical conductor, components and apparatus for
conveying electric power from the source to the point of use. Power is supplied domestic installation through a
phase and a neutral forming a single phase A.C 230 V two wire system.
For industrial establishment, power is supplied through three-phase wire system to give 440 V. The neutral is
earthed at the distribution substation of the supply. When supplied to domestic utilities, phase is fed to a kilowatt
meter and then to a distribution panel. The panel distribution passes along with circuits.
Elements of House Wiring:
1. Fuses and circuit breakers:
These are devices designed to provide protection to a circuit against excess current.
2. Electric Switch:
This is a device that makes and breaks or changes the course of electric circuit
3. Plug:
It is a device carrying two or three metallic contacts in the form of pins, intended for engaging with
corresponding socket contacts and arranged for attachment to appliances such as radio, T.V fan etc.,
4. Socket out let:
It is a device carrying two or three contact designed for engagement with corresponding plug pins and arranged
for connection to fixed wiring.
5. Lamp Holder:
Lamp Holder is designed to hold lamps and connect there in the circuit.
6. Main Switch:
This is a switch intended to connect or cut off the supply of the electricity to the whole of insulation. It contains
one or more fuses.
MECH EWS 54
WIRES AND WIRE SIZES
An electric wire is an insulated conductor consisting of one or several strands. The insulation material is
made of vulcanized India rubber (VIR) or polyvinyl chloride (PVC). The wire may consist of one or several
twisted strands. A multi-core conductor consists of several coresinsulated from one another and enclosed in a
common sheathing.
Wire sizes are specified by the diameters of the wire, using a standard wire gauge (SWG), which also gives an
idea of the current carrying capacity. The specification consist of both the number of strands and the diameter of
each wire in it. For example the specification i. silk wire 14/36 consist of 14 strands of 36 gauge each and ii. 3/18
PVC consist of 3 strands of 18 gauge each.
WIRING METHODS
There are 3 types of electric circuits that are used for connecting devices or controls to the power source viz,
series circuit, parallel circuit and the combination of two.
The series circuit provides a single, continuous path through which current flows. In this the devices are
connected one after another and the current flows through them until it returns to the power source. In this, even
one device breaks down, the remaining devices will not operate, because the circuit is broken. In parallel circuit
the devices are connected side by side so that current flows in a number of parallel paths. In this type of circuit, each
devices connected acrossthe power source so that even if one device breaks down, the other device continue to operate.
Hence, this type of circuit is used in house wiring. The wires used in house wiring contain multistrand copper
wires, covered with PVC insulation
MECH EWS 55
PARTS OF A CABLE
1. Conductor
2. Insulation covering and
3. Protective covering.
STRANDED CABLE
Electrical energy is supplied from the generating station to the consumer by means of cable. The conductor of the
cable is of two types.
1. Solid conductor, and

2. Stranded conductor
In a solid conductor cable, there is only one conductor. But in stranded conductor cable, it is made of a
number of strands of wires of circular cross section so that it is flexible.
Advantages of stranding cables
1. Thin wires can be used which increase the flexibility of the cable.
2. Provides ease in handling during installation and erection work.

3. Facilitates making joints
4. If a conductor breaks, there are other conductors to which current can pass and thus there is
no complete break down.
5. It provides ease in soldering joints.
Core of a cable
The core of a cable is single conductor of a cable with its insulation but not include any mechanical
protective covering.
Colour code for cores
For identification of multi core cables having wires of different polarities, the cores are allotted different
core colours.
In a three phase, four wiring system, the three phases 1,2, and 3 are given the core colours red,
yellow and blue respectively. Foe a neutral wire, the colour of the insulation is black, and green for earth
wire. These core colours should always be kept in mind while connecting conductors in multi core cables.
MECH EWS 56
Size of a cable
The size of a cable depends on the size of the conductor. It is determined by one of
thefollowing.
1. With a standard wire gauge,

2. According to the diameter of the conductor, and
3. According to the cross sectional area of the conductor.
Types of cables
The following cables are used for different types of wiring installation
1. V.I.R. (Vulcanized insulation rubber) cable

2. C.T.S (Cab type sheathed) cable
3. P.V.C(Poly vinyl chloride) cable
COMMON HOUSE WIRING CONNECTIONS
One lamp controlled by a one –way switch:
Figure shows the wiring diagram for a lamp controlled by a one-way switch. This is the normal
connection one comes across in house wiring.
Two lamps connected in series or parallel by a one-way switch:
Two lamps may be connected by one –way switch in parallel for bright glow or in series for
dullglow.
MECH EWS 57
One lamp controlled by 2 two-way switches
It is sometimes desirable to control a lamp from two different places. One may come across this situation with staircase, long
corridors or hall containing two entrances etc.
MECH EWS 58
MECH EWS 59
MECH EWS 60
MECH EWS 61
Safety Precautions
1. When closing the electric switch, always grasp the switch, by the insulated handle.
2. Do not run too many electrical items from one point.
3. Use fuses and circuit breakers of proper capacity so as to interrupt the current before
itbecomes dangerous.
4. Disconnect the units to be repaired free from power supply and make sure that they
mightnot be energized while the repair work continues.
5. Do not pour water to put off fires in electric wires and electric equipment. You will be
subjected to electric shock or you will be electrocuted. You sand to put off fires
inelectric items.
6. Whenever there is power failure, put off the power supply to all equipment, in order
toprevent spontaneous recovery.
7. Never remove a plug from an outlet by pulling the cord. Always pull by the plug.
8. While testing, always keep one hand in the pocket. If both the hands are contact with
acircuit, a current will flow across your body and is more dangerous.
9. Electricity has no respect for ignorance. Do not apply voltage or turn ON any device
untilit has been properly tested.
Check the earth connection before switching on portable equipment like drill guns etc
MECH EWS 62
Experiment – 01
Aim: To prepare a wiring to control two lamps connected in series by one switch.
Tools required: Screw driver, connector, tester, lamp holders, one way switch, wires, nails,
pocker,bulbs, wire cutter, nose plier, cutting plier, ball peen hammer.
Circuit diagram:
Sequence of Operations:
1. The out line of the wiring diagram is marked on the wooden wiring board.
2. Clips are nailed to the board, following the wire diagram.
3. Wires are stretched and clamped with the clips.
4. Wires are connected to the holder and the switch as shown in above diagram, which
arethen screwed on the board.
5. Bulbs are fitted to the holders.
6. The wiring connections are tested by giving power supply.
Precautions:
2. Whenever there is power failure, put off the power supply to all equipment in order
3. Put on mains only after ascertaining completion of correct wiring.
MECH EWS 63
Experiment – 02
Aim: To prepare a wiring to control two lamps connected in parallel by one switch.
Circuit diagram:
are then screwed on the board.
Precautions:
1.Never remove a plug from an outlet by pulling the cord. Always pull by the plug.
2Whenever there is power failure, put off the power supply to all equipment in order
3Put on mains only after ascertaining completion of correct wiring.
MECH EWS 64
Experiment – 03
Aim: To give connections to one lamp controlled by two 2-way switches
Circuit diagram:
arethen screwed on the board.
Precautions:
2. Whenever there is power failure, put off the power supply to all equipment in order to
prevent spontaneous recovery.
3. Put on mains only after ascertaining completion of correct wiring.
MECH EWS 65
FOUNDARY
INTRODUCTION
Foundry is a process of forming different shapes and sizes of metals in their molten state. It is also
called as metal casting. The shape of the metal cast obtained depends on the shape and size of the cavity
produced in sand mould by using a wooden model. This wooden model is called a pattern.
The foundry process involves three steps:
i) making the required pattern

ii) moulding process to produce the cavity in sand using the pattern
iii) pouring the molten metal into the cavity to get the casing
Pattern
A pattern is normally a wooden model which is the facsimile of the cast/product to be
made.There are many types of patterns and are either one piece or two-pieces.
Moulding Box
A moulding box is normally a rectangular wooden/metal box with bottom and top
surfacesopen. The upper part (cope) and the lower part (drag) are aligned properly.
Sieve
A sieve is used to remove foreign materials from the moulding sand. A sieve is a
rectangularor circular frame with a wire mesh.
Rammer
A rammer is used to press or ram the moulding sand uniformly into the moulding box.
Strike-off Bar
A strike off bar is a flat-edged rectangular bar made of wood. It is used to remove excess
sandon top of the mould box after ramming.
Vent wire
A vent wire is a steel wire used to produce holes in sand fill after ramming. This enables the gases to escape out to
the atmosphere when the molten metal is poured into the cavity of the mould.
MECH EWS 66
Draw spike
A draw spike is a steel spike with sharp pointed end. This is used to pick the pattern from themould after
ramming
Mallet
A mallet is used to give light blow to the draw spike to drive it into the pattern in order to lift
thepattern with the help of draw spike. It is round or rectangular and is made of hard wood.
Lifter
A lifter is used to remove the loose sand in the cavity produced in moulding. It is also used
tofinish the walls of the cavity after removing the pattern.
Trowel
A trowel is used to finish the cavity obtained in the mould. Trowels of various shapes and
sizesare used in moulding process.
Sprue Pin and Runner
A sprue pin is a cylindrical and tapered wooden piece used to make a hole through which the
molten metal is poured into the mould cavity.
Core
The core is used to make a hole or hollow casting. The core is normally made of core sand. The
core sand can be removed easily after the casting. The core sand is having 90% silica sand and
the remaining is binding materials (saw dust, asbestos, linseed oil, molasses etc.)
MECH EWS 67
Shovel
It is used to mix and move the mould sand from one place to another in the foundry shop.
Itconsists of a broad iron pan fitted with a long wooden handle.
Bellow
It is used to blow out sand particles and dust on the surface of the mould.
Swab
It is used to apply water on the edges of the pattern before removing it from the mould. It is
easyto remove the moisturized pattern, otherwise mould sand sticks along with the pattern.
Slick
It is used to repair and smoothen the mould surface after removing the pattern. It consists
of spoon shaped double ended trowel.
Gate cutter
It is used to cut gates in the mould. The gate is connecting the runner hole and themould
cavity.
Melting furnaces
The melting furnaces are used to melt the metal to be cast. Furnaces used to melt ferrous
ornon-ferrous metals are
a) Coke fired crucible furnace

b) Oil fired crucible furnace
c) Gas fired crucible furnace
d) Cupola furnace
e) Electric furnace etc.
MECH EWS 68
MECH EWS 69
Experiment No:01
AIM: To prepare a mould cavity for the given single piece pattern.
MATERIAL REQUIRED: Natural sand, bentonite , chalk powder
TOOLS REQUIRED:
1. Molding sand 2. Ramming rod
3. Gate cutter 4. Spike rod
5. Vent rod 6. Mallet
7. Shovel 8. Riddle
9. Bellows
PROCEDURE:
1. The given pattern is checked for the correctness

2. Place the first half of the pattern in the inverted drag box and fill with molding sand.
3. Prepare the cope box also in the similar way.
4. Sprinkle parting sand over the top face of the drag box.
5. Place the runner and riser in the appropriate places in the mould box before
pouringthe sand.
6. Then by using vent rod keep the vent holes to allow the casing gases to escape.
7. Now the pattern is removed from the mould box which will give the mould cavity.
8. After cavity is prepared, prepare sprue and also cut the gates by using gate cutter.
9. Finally place the cope box over the drag box for the completion of the experiment.
RECAUTIONS:
1. Do not keep the tools at the edge of the work-be
2.Do not over ram the molding sand
MECH EWS 70
Experiment No:02
AIM: To prepare a mould cavity for the given split pattern.
MATERIAL REQUIRED: Molding sand, bentonite
TOOLS REQUIRED:
7. Shovel 8. Riddle
9. Bellows
PROCEDURE:

3. Prepare the cope box also in the similar way by placing the other half of the pattern.
5. Place the runner and riser in the appropriate places in the mould box before
pouringthe sand.
7. Now the two pieces of the pattern are removed from the mould box which will give
themould cavity.
PRECAUTIONS:
1. Do not keep the tools at the edge of the work-bed.

MECH EWS 71
Experiment No:03
AIM: To prepare a mould cavity for the given pattern.
MATERIAL REQUIRED: Natural sand, bentonite , chalk powder
TOOLS REQUIRED:
7. Shovel 8. Riddle
9. Bellows
PROCEDURE:

3. Prepare the cope box also in the similar way by placing the other half of the pattern.
5. Place the runner and riser in the appropriate places in the mould box before pouring
thesand.
7. Now the two pieces of the pattern are removed from the mould box which will give
themould cavity.
PRECAUTIONS:
1. Do not keep the tools at the edge of the work-bed.

2. Do not over ram the molding sand
MECH EWS 72
VIVA – VOICE
1. Green sand used for making a mold is green in color

(stateTRUE/FALSE) Ans: FALSE
2. The upper part of the molding flask is known as Ans: cope
3. The middle part of the molding flask is known as Ans: cheek
4. The tool is used to repair the mold is Ans: slick
5. are provided in a mold to enable hot gasses to escape while

pouringAns: vents
6. State different properties of the sand
MECH EWS 73
WELDING
Introduction
Welding is metal joining process wherein localized coalescence is produced either by heating
the metal to a suitable temperature, with or without the use of filler metal, with or without
application of pressure.
The filler material has similar composition and melting point temperature as that of the base
metal. It is used to fill gap between the joint surfaces.
Types of welding
The welding process is divided into two main sub divisions.
Plastic welding
The pieces of metal to be joined are heated to the plastic state and then forced together by
external pressure without the addition of filler material.
Forge welding
The work piece are placed in a forge or other appropriate furnace and heated within the area
to be joined to the plastic condition. Then parts are quickly superimposed and worked into a
complete union by hand or power hammering or by pressing together.
Resistance welding
In resistance welding, a heavy electric current is passed through the metals to be joined over
limited area, causing them to be locally heated to plastic state and the welding is completed by
the application of pressure for the prescribed period of time.
Fusion welding
In fusion welding, the metal parts to be joined are melted and then allowed to solidify pressure
is not applied and filler metals may be used for this type of welding.
Gas welding
Gas welding is a process in which the required heat to melt the surfaces is supplied by a high
temperature flame obtained by a mixture of two gases. Usually the mixture of oxygen and
acetylene is used for welding purpose.
Electric Arc welding

Electric arc welding is the process of joining two parts by melting their edges by an
MECH EWS 74
electric arc with ort without the application of pressure and with or without use of filler metals.
Thermit welding
Thermit welding is a fusion process in which weld is effected by pouring super heated liquid
thermit steel, around the parts to be united with or without the application of pressure.
In oxy-acetylene welding oxygen and acetylene are the two gases used for producing
flame.Oxygen is mainly used for supporting the combustion intensity.
The oxygen and acetylene under high pressure in cylinders which are fitted with pressure
regulator. Each cylinder is connected to the blowpipe by flexible hoses. The oxygen cylinders
are painted black and acetylene cylinders are painted maroon. When acetylene is mixed with
oxygen in correct proportions in the welding torch, ignition is takes place. The flame resulting
at the tip of the torch is sufficient enough to melt and the parent material .The flame
temperature is about 3200ºC.The filler metal rod is generally added to the molten metal pool to
built up the seam for greater strength.
Types of flames
1 .Neutral Flame (Oxygen, Acetylene in equal proportions)
2. Oxidizing Flame (excess of Oxygen)
3. Reducing Flame (excess of Acetylene)
MECH EWS 75
Neutral Flame
A neutral flame is produced when approximately equal volumes of oxygen and acetylene are
mixed in the welding torch and burnt at the torch tip. The temperature of the neutral flame is of
the order of about 3260ºC. The flame has inner cone which is light blue in color. The neutral
flame is used for welding of mild steel, copper, aluminum, cast iron, etc.
Oxidizing Flame
If the volume of the oxygen supplied to the neutral flame is increased, then resulting flame will
be oxidizing flame. The temperature of oxidizing flame is of the order of about
3482ºC.Normallythe outer flame envelope is much shorter. It has very small white inner cone.
This flame is usedto weld copper-base metals, zinc-base metals.
Reducing Flame (Carburizing Flame)
If the volume of the oxygen supplied to the neutral flame is reduced, the resulting flame will be
reducing flame.
In this case, flame is recognized by acetylene feather which exists between the inner cone and outer envelope. The
outer flame envelope is longer than that of the neutral flame and is usually much brighter in color. It has an
appropriate temperature of 3038ºC. In this type, flames are used to weld the high-carbon steel, non-ferrous alloys,
zinc bearing alloys.
MECH EWS 76
Filler metal
It is the material that is added to the weld pool to assist in filling the gap. Filler metal forms an
integral part of the weld. The filler metal is usually available in rod form. The rods are called
filler rods.
Fluxes
During the welding, if the metal is heated in the air, oxygen in the air combines with the
metal 5to form oxides which result in poor quality, low strength welds or in some cases
mayeven make welding impossible. In order to avoid this problem, a flux is added during
the welding. The flux prevents oxidation by preventing oxygen from contacting the weld
zone. No flux is used in the gas welding of steel. The most commonly used flux materials
are boricacid, soda ash and sodium chloride.
Comparison of A.C and D.C arc welding equipments
S.No Alternating current(AC) Direct current(DC)
It is not suitable for both ferrous and

1 It is not suitable for joining non-ferrous non-ferrous metals.
metals.
Bare electrodes can also be
2 Only coated electrodes can be used. used.
3 Consumes less power Consumes more power.
4 High efficiency. Low efficiency.
5 Cost of equipment is less. Cost of equipment is more.
6 Noiseless operation. It gives noise.
Suitable for welding thin

7 Not suitable for welding thin sections. sections.
MECH EWS 77
Electrodes
Filler rods are used in arc welding are called as electrodes. The Electrodes are made of metallic
wire called core wire. It is uniformly with a protective coating called flux while fluxing an
electrode about 20 mm of length is left bare at one end for holding it using electrode holder. It is
used to transmit full current from electrode holder to the front end of the electrode coating.
Electrode Holder
It is a device used for mechanically holing the electrode and conducting current to it.
Electrode holder should be light, to minimize fatigue incurred by the welder. Jaws are
made to hold the bare end of the electrode in either at vertical or at an angular position.
Welding Cables
Two cables are needed for welding purpose. One is used to connect the
powersource to electrode; another cable is connected to ground.
The cables are well isolated with rubber.
Welding Bead cleaning accessories
MECH EWS 78
Chipping hammer
A chipping hammer is chisel-shaped one and it is used to remove the slag from the weld bead.
Wire Brush
A wire brush made up of stiff steel wire, embedded in wood, removes small particles of
slagfrom the weld bead after the chipping hammer is used.
Hand Screen
It is a protective device used in arc welding. A hand shield is held in the hand of the
welderand it is fitted with a suitable fitter lens.
Helmet
It is used for shielding and protecting the face and neck of the welder and it is fitted with
asuitable fitter lens.
Tongs
Tongs are used to handle the hot metal-welding job while cleaning; they are also used to
holdthe metal for hammering.
Goggles
Chipping goggle is used to protect the eyes while chipping the slag. They are fitted while a
plainglass to see the area to be cleaned.
Hand Gloves
Hand gloves are used to protect the hands from electrical shock, arc radiation and hot spatters.
MECH EWS 79
EXPERIMENT 01
Aim: To join the given two work pieces as a lap joint by arc welding.
Material used: Mild Steel plates.
Tools required
1. Welding power supply 2. Flat file Welding rod 3. Chipping hammer
4. Electrode holder 5. Wire brush 6. Gloves and apron
7. Earthing clamps 8. Shield and goggles
Procedure
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and
otherforeign materials.
2. Then the given work pieces are placed on the table in such a way that one work piece
isplaced on the other work piece like the LAP joint is formed.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Then the welding is carried out throughout the length.
7. As soon as the welding process is finished, switch off the current supply and allow
thework piece to cool.
8. Slag is removed by chipping process with the help of chipping hammer.
9. Finally using wire brush, welded portions are cleaned.
Result Thus the given two work pieces are joined as a lap joint by arc welding.
MECH EWS 80
EXPERIMENT 02
Aim: To join the given two work pieces as a single v butt joint by arc welding.
Material used: Mild Steel plates.
Tools required
1. Welding power supply 2. Flat file Welding rod 3. Chipping hammer
4. Electrode holder 5. Wire brush 6. Gloves and apron
7. Earthing clamps 8. Shield and goggles
Procedure
1. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and
otherforeign materials.
2. Then the given work pieces are placed on the table in such a way that work pieces are
brought close to close to each other so that it forms a V shapes when the plates butt each
other.
3. Appropriate power supply should be given to the electrode and the work pieces.
4. Now the welding current output may be adjusted.
5. When current is passed, arc is produced between the electrode and work pieces.
6. Now set the two work pieces in correct position and maintain the gap 3mm and tag at
bothends of the work pieces as shown in figure.
7. Then the welding is carried out throughout the length.
8. As soon as the welding process is finished, switch off the current supply and allow
thework piece to cool.
9. Slag is removed by chipping process with the help of chipping hammer.
10. Finally using wire brush, welded portions are cleaned.
Result: Thus the required „single V butt joint‟ is made by arc welding process.
MECH EWS 81
VIVA - VOICE
Name the types of welding? Ans:

(i) Arc welding
(ii) Argon
welding(Iii) Gas welding
(iv) Tig welding
(v) Mig welding
(vi) Spot welding
Which is the welding process you have carried out in workshop? Ans:
Electric arc welding
What is welding?
Ans: Joining of two similar metals
Name the welding tools used in workshop?

Ans: Welding holder, welding rod, hand screen, hand gloves, chipping hammer, wire brush
Which outer cover is on the welding rod? Ans:Silicon
MECH EWS 82
POWER TOOLS IN CONSTRUCTION, WOOD WORKING, ELECTRICAL ENGINEERING

AND MECHANICAL ENGINEERING
INTRODUCTION
Portable power tools are widely used in various fields of engineering. There are many
manufactures supplying the same with wide range of products. One should be careful in
selecting the tools. Double installation tools are recommended for safety. Selection of range or
capacity is also important depending upon the application. The following are the some of the
fields of use.
(a). Simple drilling operation
(b). Hammer drilling in hard building materials and concrete, (c).
Carpentry work involving
(i). Planning (ii). Cutting (iii). Sander etc (d).
Marble cutter
(e).Various types of grinders (f).
Blowers
(g). Screw driver
1. Drills (wood and metal): These are used for drilling holes in wood/metal.
Capacity: Steel:
10 mm
Wood: 25 mm
Powerinput: 420 W
Speed:
2800 rpm Weight:
1.4 kg
MECH EWS 83
2. Impact drills (concrete and brick): These are used for making holes in concrete and
bricks. Impact drills with multipurpose application are used for general drilling as well
asimpact drilling.
Capacity: Concrete:
15 mm
Steel: 10 mm
Powerinput: 520 W
Speed:
2900 rpm
Weight: 1.6 kg
3. Hammer drills (concrete and brick): These are heavy drills for making holes
continuouslywith bigger size drills up to 38 mm. It has keyless drill check.
Capacity: Concrete:
24 mm
Power Input: 500 W
No-load speed: 0~1000 blows per min Weight:
2.3 kg
4. Masonry cutter: These are used for cutting to size floor tiles, granite stone, slabs or
tilesetc.
Capacity:
Wheel diameter: 110 mm
Maximum cut depth: 34
mmPower input: 1050 W
Speed:
11000 rpm
Weight: 2.6 kg
5. Circular saw (wood): this is used to cut wood
Capacity:
Blade diameter: 185 mm
MECH EWS 84
Max cut depth: 65 mm
Powerinput: 1050 W
No-load Speed: 4700
rpmWeight: 3.9 kg
6. Compound mitre saw (wood): This is used for precision cutting and any angle cutting.
Capacity:
Blade diameter: 255 mm
0
Max cut depth: 0 cross cut 67x145 mm Compound:
0 0
45 x45
Power input: 1640 W Speed:
5000 rpm
Weight: 14 kg
7. Jig saw (wood and metal): This power tool is used to cut along a line it can also be used
0
for bevel cutting 0 ~ 45 right/left.
Capacity:
Max cut capacity: Wood:
600 mm
Steel: 6 mm
Bevel cutting: 0 ~ 45 (right/left)
Powerinput: 400 W
Speed: 2700/3200 rpm Weight:
2.1 kg
8. High speed cut of machine (metal): This is versatile tool to cut metal with speed
andaccuracy. Very much in use to cut torsion rods in building construction at site.
Max cut capacity:
Wheel diameter: 250 mm
Powerinput: 2000 W Speed:
3700 rpm
Weight: 17.5 kg
MECH EWS 85
9. Chain saw (wood): this is used for continuous sawing of wood. Mostly used for
fellingtrees.
Capacity: 350 mm (Bar

size) Power input: 1140 W
Speed:
450 m/min
Weight: 4.2 kg
10.Orbital sander (metal and wood): This versatile tool is used for smooth finishing
of wood and metal surfaces which is given orbital action for fast and smooth finish on
plainsurfaces.
Capacity; 110 x 100 mm (Pad

size)Power Input: 180 W
No- load speed: 24,000/min (Orbit) Weight:
1.1 kg
11.Disc sander (wood): Used to give smooth finish to wood surface with sand discs
mounted and rotated in circular motion unlike orbital sander. It can reach irregular
shapes and spaces.
Capacity: 150 mm (Sanding disc)

Powerinput: 530 W
Speed: 4000/min Weight:
3.2 kg
12. Sand polisher: This is used for polishing wood surfaces.
Capacity: 180 mm
Power Input: 750 W
Speed:
1900/3400/min
Weight: 2.9 kg
MECH EWS 86
13.Disk grinder (Metal): Used for grinding metal to give required shape finish especiallyafter
welding.
Capacity: 115 mm (wheel dia)

PowerInput: 750 W
Speed:
10,000/min
Weight: 2.1 kg
14.Hand grinder (Metal): This is a versatile power operated portable grinder which can be used in
number of ways for both internal and external grinding of various contours by suitably
changing the mounted chuck.
Capacity: 6 mm (collect chuck)

Wheeldiameter: 25 mm
Power input: 520
WSpeed:
25000/min
Weight: 1.8 kg
15.Planer wood: this is used for power planning of wooden surfaces in the place of hand jackplane.
Capacity:
Cutting width: 82 mm
Cutting depth: 1 mm
Powerinput: 570 W
Speed:
15000/min Weight: 2.5 kg
16.Screw driver: This particular tool is used to drive screws in wood or sheet metal. It canalso
be used for removing the screws by reversing the rotation.
Capacity:
Wood screw: 5.8 mm
Drywall screw: 5 mm
Self drilling screw: 6
mm
MECH EWS 87
Power input: 520
WSpeed:
2600/min Weight:
1.7 kg
17.Blower: blowers are used for cleaning and maintenance with dust bags to collect thedust.
Capacity:
Air pressure: 400 mm Air
3
volume: 2.3 m /min Power
input: 355 W Speed:
13000/min Weight: 1.8 kg
MECH EWS 88
TRADES FOR DEMONSTRATION AND EXPOSURE PLUMBING
Introduction
Plumbing deals with the laying of a pipeline. A craftsman may be perfectly proficient with the hammer,
saw and other tools, but the faces difficulties with leaking pipes and overflowing toilets. Many people rush to a
plumber on seeking a tripping pipe, but a person with a little knowledge of the sanitary system can control this
problem easily, saving time and, one with helpof few tools.
Plumbing tools
The tools used by a plumber can be classified as follows
1. Pipe wrench 4. Pipe vice 7.Files and Rasps

2. Hacksaw 5. Dies
3. Plumb bob 6. Pipe cutter
Pipe wrench
A pipe wrench is used for holding and turning the pipes, rods and machine parts. Wrenches are classified as
follows.
1. Fixed wrenches 2. Adjustable wrenches.
Pipe vice
A pipe vice is fitted on the work bench. This has a set of jaws to grip the pipe and prevent it from turning while
cutting, threading and fitting of bends, couplings etc. The yoke vice is commonly used in plumbing used in
plumbing practice.
MECH EWS 89
Pipe cutter
The pipe cutter mainly consists of three wheels which are hardened with sharp cutting edges along their periphery.
Of these three wheels, one can be adjusted to any desired distance to accommodate different size of pipes. After
adjusting the cutter on a pipe, it is around the pipe, so that the cutter wheels cut the pipe along a circle as shown in
fig.
Hack saw
A hacksaw is used for cutting metal rods, bars, pipes, etc
Plumb bob It is used for check the vertical line and made up of steel or brass.
MECH EWS 90
Pipe fittings
Pipe fittings are made up of wrought iron. The size of pipe fitting is designated by the size of the pipe on which it
fits. some of the common pipe fittings are shown in fig.
Coupling
It is a short a cylindrical sleeve with internal threads throughout. A couplings is used for joining two pipes in a
straight and bend where at least one pipe can be turned.
Union
A union is used for joining two pieces of pipes, where either can be turned. It consists of three parts, two parts
joint can be screwed, in to two pipe ends, and the third on for tightening called centre part
MECH EWS 91
Nipple
A nipple is a short piece of pipe with external threads at both ends. It is used to make up the required length of a
pipe line
Elbow
An elbow is to make an angle between adjacent pipes.
Tee
A tee is a fitting that has one side outlet at a right angle to the run. It is used for a singleoutlet branch pipe.
Reducer
It is used to connect two different sized of pipes
Plug
It is used to screw on to a threaded opening, for closing it temporarily.
Valves
Valves are used for regulating the flow of fluid through a pipe. The commonly used valvesin plumbing‟s are
1 Gate valve 2.Globe valve

.
3 Plug valve 4.Check valve 5. Air relief valve.
.
Types of pipe joints

A connection between two sections of pipe i.e. the straight spigot end of one section is inserted into the flared out
end of the adjoining section. The joint is sealed by a sealing component.
Flanged joints
A flanged joint helps to connect and disconnect two pipes as per the need. A similar exampleis as shown in fig.
The use of bolted joint is advantageous in the following circumstances

1. The component that cannot be serviced in line.
2. The components being joined that are not capable of being welded.
3. Quick field assembly is required.
4. The component or pipe section that needs to be frequently removed for surface
Threads are cutted in a pipe, flange coupling to connect them with each other these joints are and called
threaded joints
Flexible joints
The flexible joints are generally used to connect between a washbasin and an angle valve.
MECH EWS 92
Swing joints
Swing joints are special purpose joints mainly used for industrial oriented purposes where
along bend is required.
Welded and brazed joints are the most commonly used joints for joining pipe components.
Expansion joints
Expansions joints are specially designed in pipeline where a small extension of
pipeis required
MECH EWS 93
MECH EWS 94
MECH EWS 95
MECH EWS 96
VIVA - VOICE
How the pipes are specified?

Ans: (i) Material
(ii) Inside diameter
(iii) Wall thickness
(iv) Length
which is the common pipes used nowadays?

Ans: (i) C pvc
(ii) U pvc
Which vice used in plumbing

Ans: Pipe vice
Name only five fittings?Ans:

(i) Elbow
(ii) Tee
(iii) Union
(iv) Coupling
(v) Reducer
5 What is B.S.P.?
Ans: British Standard Pipe
MECH EWS 97

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GURUNANAK INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

ENGINEERING WORK SHOP MANUAL (22ES0ME01)

 Always put on protective glasses or goggles for eye protection.

 Use earplugs or muff when carrying out hot work.

 Do not put on loose cloths when entering the workshop.

 Do not wear jewellery when working in the workshop.

 Do not put on rings when working in the workshop.

 Do not keep a loose hair when working in the workshop.

 Do not wear bracelets while working in a workshop.

 Develop the faculty to reach the international standards.

 Offer collaborative industry programs in emerging areas and spirit of enterprise.

The Vision of the Mechanical Engineering department

 To be a leading department of Mechanical Engineering in the region

The Mission of the Mechanical Engineering department

2. Nurture the faculty to expose them to world-class infrastructure.

3. Sustain high performance by excellence in teaching, research and innovations.

Programme Educational Objectives

d. An ability to function on multidisciplinary teams.

e. An ability to identify, formulate, and solve engineering problems.

f. An understanding of professional and ethical responsibility.

g. An ability to communicate effectively.

i. Recognition of the need for, and an ability to engage in life-long learning.

j. A knowledge of contemporary issues

ENGINEERING WORKSHOP SYLLABUS

Course Code 22ES0ME01

 To Study of different hand-operated power tools, uses and their demonstration.

1. TRADES FOR EXERCISES:

II. Fitting – (V-Fit, Dovetail Fit & Semi-circular fit)

III. Tin-Smithy – (Square Tin, Rectangular Tray & Conical Funnel)

V. Welding Practice – (Arc Welding & Gas Welding)

VII. Black Smithy – (Round to Square, Fan Hook and S-Hook)

2. TRADES FOR DEMONSTRATION & EXPOSURE:

1. Workshop Practice /B. L. Juneja / Cengage

1. Work shop Manual - P. Kannaiah/ K.L. Narayana/ Scitech

Single piece pattern

Characteristics of Good Timber

Steel rule and Steel tape

Figure : Steel rule and Steel tape

a. Marking gauge b. Mortise gauge

Figure : Try square

Compass and divider

Figure : bar cramp

Figure : Types of planes

Cross‐cut or hand saw

Figure : Types of saws

DRILLING AND BORING TOOLS

Aim: To make Cross Lap joint as per dimensions

Material Required: Teak wood 35 mm x 50 mm x 300 mm

The given wood is checked to ensure its correct size.

Aim: To make dove tail joint as per dimensions

Material Required: Teak wood 35 x 50 x 300 mm

The given wood is checked to ensure its correct size.

Material Required: Teak wood 35 x 50 x 300 mm

The given wood is checked to ensure its correct size.

8. The parts are fitted to obtain a slightly tight joint.

(i) Marking ii)Sawing iii)Planning iv) Chiseling v)Grooving

Figure : Bench Vice

Figure : V‐block Figure : C‐clamp

MARKING AND MEASURING TOOLS

Figure : Surface plate Figure : Angle pla

Odd leg Caliper

Figure : Odd leg caliper and divider